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The PO Production Chain and Possibilities for Energy Saving

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The PO Production Chain and Possibilities for Energy Saving The PO production chain and possibilities for energy saving Public Summary Report Delft, January 2012 Author(s): Ewout Dönszelmann Ab de Buck Harry Croezen Lonneke Wielders Publication Data Bibliographical data: Ewout Dönszelmann, Ab de Buck, Harry Croezen, Lonneke Wielders The PO production chain and possibilities for energy saving Public Summary Delft, CE Delft, January 2012 Energy saving / Chain Management / Products / Chemical industry / Propylene Oxide / Styrene / Iso-butylene FT: Tert-butyl alcohol (TBA) Publication code: 12.2232.12 CE publications are available from www.cedelft.eu. Commissioned by: Agentschap NL Further information on this study can be obtained from the contact person, Ewout Dönszelmann. © copyright, CE Delft, Delft CE Delft Committed to the Environment CE Delft is an independent research and consultancy organisation specialised in developing structural and innovative solutions to environmental problems. CE Delft’s solutions are characterised in being politically feasible, technologically sound, economically prudent and socially equitable. 2 January 2012 2.232.3 – The PO production chain and possibilities for energy saving Contents 1 Introduction 5 1.1 General background 5 1.2 The project 5 1.3 Approach 6 1.4 Reading guide 6 2 The production chains 7 2.1 The two processes 7 2.2 Expanded polystyrene 9 2.3 Polyols 11 2.4 TBA/iso-butylene applications 13 3 Conclusions, recommendations 17 3.1 Conclusions 17 3.2 Recommendations 17 4 Background of the Long-term Agreement Energy Efficiency ETS enterprises (LEE) 19 References 21 3 January 2012 2.232.3 – The PO production chain and possibilities for energy saving 4 January 2012 2.232.3 – The PO production chain and possibilities for energy saving 1 Introduction 1.1 General background The Dutch Industry and the Dutch government have made long term agreements on energy efficiency (LEE) for companies that are under the European Trading Scheme (ETS). These companies have to report frequently on their possibilities and achievements on energy efficiency. These reports describe the current state of energy use, the possible measures that can be taken and the measures already taken and their results. LyondellBasell is one of the companies that take part in LEE. Lyondell Chemie Nederland B.V., as part of LyondellBasell, produces Propylene Oxide (PO) on two different production sites and in two different processes. In the Maasvlakte site PO is produced with the POSM process where Styrene is a co-product. In the Botlek site PO is produced with the PO/TBA process where tert-butyl alcohol (TBA) is the co-product. Energy efficiency can be found on the sites and in the product chain of PO, TBA and Styrene, both upstream and downstream. The LEE agreement gives companies the opportunity to assess measures both on site and in the product chain. 1.2 The project Based on the agreements of LEE linked to ETS, companies make an effort to realise a significant energy saving within their business community, and the government supports them by means of process coordination and financing additional studies. Agentschap NL coordinates the governmental support. LyondellBasell asked Agentschap NL for support in assessing their energy efficiency on site and through the chain of its products. CE Delft has been commissioned by Agentschap NL and LyondellBasell to determine the carbon footprint and cumulative energy demand of the two production sites of LyondellBasell in the Rotterdam area. Purpose of the project is to identify energy saving potential within the PO, Styrene and tert-butyl alcohol production chains. This study also focuses on those options that require cooperation with other companies or yield savings for more than one company within the PO production chains. The project was carried out in close cooperation with LyondellBasell. At all meetings Agentschap NL was represented. The project consisted of two pathways. The first assessed the possibilities of energy saving in the supply chain. Both the Maasvlakte and the Botlek site of LyondellBasell were addressed. The second pathway focused on three product chains: Styrene, Polyols and ETBE/MTBE. This report presents the results of the projects second pathway: the product chains. 5 January 2012 2.232.3 – The PO production chain and possibilities for energy saving 1.3 Approach Each assessment started with the drawing of energy charts. An energy chart is an instrument to get insight in the combined energy and mass flows in the production chain. These energy charts give an overview of the energy content of each process step as well of the energy content of the feedstock and the products. Using information from open source literature and data provided by LyondellBasell, each process step was worked out in more detail resulting in a map of the major mass and energy flows involved. These flows are presented as energy charts. The charts give an indication of the mass and energy flows involved and the level of detail allowed for by this approach. In total two brainstorm sessions have been conducted and one special paper was produced. The brainstorm sessions focused on the possibilities of energy saving in the chain. The paper was on ETBE, MTBE and ethanol comparison. After the brainstorms, possible measures were drawn up based on the suggestions made during these sessions, targeting both the energy saving potential and the technical and economic feasibility of the measure. The measures were reported to LyondellBasell. 1.4 Reading guide This public summary is one of the six products that have been produced for Lyondell Chemie Nederland B.V.. The other five are confidential reports on the energy charts, the energy saving possibilities on site and in the production chains. The confidentiality concerns the site and production specific information. The public summary explains the chosen approach for this study in Section 1.3, the energy saving possibilities in the production chain in Section 2.2 to 2.4. Chapter 3 gives the conclusions and recommendations. 6 January 2012 2.232.3 – The PO production chain and possibilities for energy saving 2 The production chains 2.1 The two processes The general route to propylene oxide involves co-oxidation of the organic chemicals isobutylene or ethyl benzene. These processes are known as PO/TBA and POSM processes. 2.1.1 PO/TBA process In the PO/TBA process applied at LyondellBasell’s Botlek location isobutane is oxidised with industrial oxygen to tert-butyl hydroperoxide (TBHP). (TBHP) The applied raw materials are supplied by third parties: The oxygen is produced by an over the fence conventional cryogenic air separation plant and supplied by pipeline. Propylene is purchased from steam cracking installations and supplied by pipeline and by ship. The isobutane is primarily purchased from natural gas processing plants and refineries and is supplied by ship and pipeline. The produced tert-butyl hydroperoxide is next mixed with a catalyst solution to react with propylene, giving propylene oxide and TBA during this process step: The produced propylene oxide and tert-butyl alcohol (TBA) are separated by distillation after which: The TBA is dehydrated into iso-butylene, which is subsequently converted into ETBE by addition of ethanol or to MTBE by addition of methanol. The ETBE or MTBE is supplied to oil companies for blending into gasoline. The propylene oxide is partly supplied to external consumers and partly processed on site into a range of chemicals, including ethers and glycols. 7 January 2012 2.232.3 – The PO production chain and possibilities for energy saving Undesired by-products are isolated as liquid and gaseous fuels. These are either: applied on site for firing furnaces; sold to nearby CHP units which supply steam and power to LyondellBasell Botlek; or sold to cement industry as a secondary fuel. Process steam and power for the different processes are supplied by nearby gas fired STAG-CHP plants and a natural gas and residual fired CHP steam boiler with back pressure steam turbine. 2.1.2 POSM process At LyondellBasell’s Maasvlakte site, the ethylbenzene feedstock required for the applied POSM1 process is first produced by reaction of ethylene and benzene. Both feedstocks are primarily purchased from steam cracking plants in the region and are supplied by ship and pipeline (ethylene). The produced ethylbenzene is next oxidised with air into ethylbenzene hydroperoxide (EBHP). EBHP The produced EBHP is next mixed with propylene. Propylene is purchased from steam cracking installations and supplied by pipeline and by ship. The two chemicals react, forming propylene oxide and 1-phenylalcohol. After the epoxidation reaction between propylene and EBHP, propylene oxide, excess propylene, and propane by-product are distilled overhead. Propane is purged from the process and sold as a fuel and propylene is recycled to the epoxidation reaction. The 1-phenylethanol co-product, along with acetophenone from the hydroperoxide reactor, are converted into styrene by respectively dehydration and hydrogenation. 1 POSM = propylene oxide, styrene monomer. 8 January 2012 2.232.3 – The PO production chain and possibilities for energy saving A propane by-product is supplied as a fuel to the regular fuel market. Gaseous by-products and condensable organic by-products are supplied to a nearby CHP-plant, supplying steam and power to the LyondellBasell site. The POSM process also produces a large amount of waste water loaded with water soluble organic by-products and salts. The waste water is supplied to AVR together with a part of the condensable organic by-products and is burned as chemical waste. AVR claims that the burning of the waste water requires additional natural gas for achieving complete evaporation and raising the temperature of the flue gases to a required level of 1,200°C. 2.2 Expanded polystyrene 2.2.1 Production Styrene is used to produce polystyrene and in this case the expanded polystyrene (EPS) is assessed.
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